ROI Calculator

What Is Unplanned
Downtime Costing You?

Most operations don't track the true cost of reactive maintenance until a failure forces them to. Use this calculator to put a number on what early detection is actually worth to your operation.

Industry Benchmarks

Reactive vs. Planned Repair Costs

The difference between catching a failure early and reacting to it after the fact.

Note on estimated data: The cost ranges below are estimated industry averages compiled from publicly available maintenance cost studies and engineering literature. They are provided for illustrative reference only. Your actual repair costs, downtime costs, and savings will vary based on your specific equipment type, geography, labour rates, and operational conditions. These figures should not be used as the sole basis for capital allocation decisions. For figures specific to your operation, contact us directly.

Equipment Type	Reactive Failure Cost (Est.)	Planned Repair Cost (Est.)
Hydraulic SystemsBrakes, steering, lifts, presses	$50,000 – $150,000Emergency labour + rush parts + lost production	$5,000 – $8,000Scheduled downtime + standard parts
Commercial Fleet DrivetrainTransmissions, differentials, axles	$15,000 – $60,000Roadside recovery + emergency repair + lost route revenue	$2,000 – $6,000Scheduled swap during off-hours
Refrigeration & HVACCompressors, condensers, cooling units	$5,000 – $25,000+Compressor seizure + spoiled inventory + emergency call	$200 – $800Coil cleaning or service during planned downtime
Bearings & Rotating EquipmentMotors, fans, pumps, spindles	$2,000 – $15,000+Secondary damage + emergency labour + extended downtime	$50 – $400Bearing swap scheduled in advance
Industrial Compressors & PumpsHVAC plant, process equipment	$8,000 – $40,000Production halt + emergency contractor + secondary damage	$500 – $3,000Preventive service on scheduled maintenance window

Your Numbers

Calculate Your Return

Enter your operation's figures. Results update live as you type. All outputs are estimates — see the disclaimer below.

Number of Assets / Vehicles Total equipment units, vehicles, or systems in your operation

Avg. Repair Cost Per Failure (CAD $) Include parts, labour, and indirect costs per incident

Unplanned Failures Per Year (Total) Total unexpected breakdowns across your entire fleet annually

Avg. Hourly Downtime Cost (CAD $) Lost revenue or production cost per hour offline

Avg. Hours Down Per Failure How long your operation is typically offline per incident

Enter your figures on the left and your estimated annual failure cost, projected savings, and 3-year exposure will appear here with visual breakdowns.

Current Annual Failure Cost —

Projected Annual Savings —

Cost Per Asset Per Year —

3-Year Exposure —

Downtime Hours Recovered / Year —

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Est. Savings

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3-Yr Exposure

70%

Fail Reduction

// Estimated Cost Breakdown

Repair savings

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Downtime savings

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Hours recovered

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Estimates only. Results are based on an assumed 70% reduction in reactive failures — an industry-average improvement figure from maintenance engineering literature. Actual savings vary by equipment type, data quality, sensor density, and operational conditions. Contact us for an assessment specific to your dataset.

Need a Presentation-Ready Version?

The FSME Downtime Cost Calculator is a full Excel workbook with industry benchmark costs pre-filled, editable assumptions, and formatted output you can drop directly into an internal maintenance proposal or budget request.

$20

CAD — one-time

Get the Excel Version ►

Ready to See Your Real Numbers?

Export your existing sensor data and we'll run a forensic audit showing exactly where stress signatures are already present in your fleet — before the next breakdown happens.

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